HALFEN IN TUNNELS: Fixing and Installation Technology

Transcription

1 HALFEN IN TUNNELS: Fixing and Installation Technology Safety is the only solution

2 FIXINGS IN TUNNEL PROJECTS and the benefits for construction A modern industrial society requires an efficient and reliable transport infrastructure. This applies equally to both road and rail systems. Tunnel excavation projects place particularly high demands on geological assessment and on the structural design of the cross-section of the tunnel. Personal protection, fire prevention, corrosion protection, technical equipment and the durability of the structure require considerable forethought, which usually requires years of planning. Thanks to high-performance tools, machines and construction materials which are available today, tunnels can be built in a much shorter time than only a few decades ago. The long service life requirements of 100 years or more, depending on the various external influences (dynamic effects, impact loads, fire and corrosion) and the high demands on sustainability (maintenance and repair) also place the highest demands on the fixings in the tunnel. HALFEN has many years of experience in fixing technology for the most diverse requirements in tunnel projects. On the one hand, experience in fixing of safety-relevant equipment, this includes overhead (catenary) lines, service supply systems, signalling systems, lighting equipment, doors, ventilation systems or accident recovery anchors, and on the other hand, experience in the various methods of the actual tunnel construction process. This applies to the cut and cover and the traditional methods of construction, where a large number of reliable and efficient HALFEN Fixing systems have been installed to meet the stipulated project demands. HALFEN has a very large selection of system components for the concrete sector; this includes anchoring, reinforcement, lifting anchors and façade systems for permanent and positive load connections. To meet the rapidly growing demand, HALFEN also offers a large number of application solutions for transporting precast wall elements and base tubbing segments. Furthermore HALFEN has a wide range of façade element fixings as well as various products for efficient fixing of most precast elements. HALFEN Framing channel technology with adaptable types of bolt connections and quick and easy adjustable fixings including pre-assembled connections provide a very economical system solution for the installation of tunnel equipment. The HALFEN team of specialist tunnel engineers ensures there is technical support at all times. 2

3 Contents INTRODUCTION Fixings in Tunnel Projects Benefits for Construction Page 2 APPLICATION OF HALFEN PRODUCTS: RAIL TUNNELS APPLICATION IN RAIL TUNNELS Overview of HALFEN Applications Page 4 5 HALFEN PROJECTS Lötschberg Base Tunnel, Switzerland Page 6 Shenzen Metro Line, China Page 8 Finnetunnel, Germany Page 10 Albaufstiegstunnel, Germany Page 12 Allegheny North Shore Connector Tunnel, USA Page 14 Brenner Base Tunnel, Austria Page 16 Antwerp North-South Link, Belgium Page 18 APPLICATION OF HALFEN PRODUCTS: UTILITY TUNNELS APPLICATION IN UTILITY TUNNELS Overview of HALFEN Applications Page HALFEN PROJECTS Power Station, Lausward, Germany Page 22 Turtmann Tunnel, Switzerland Page 24 Bewag Tunnel, Germany Page 26 APPLICATION OF HALFEN PRODUCTS: ROAD TUNNELS APPLICATION IN ROAD TUNNELS Overview of HALFEN Applications Page HALFEN PROJECTS Ulricehamn Tunnel, Sweden Page 30 Horental road tunnel, Switzerland Page 32 Noise protection enclosure / A1, Germany Page 34 HALFEN PRODUCTS: IN TUNNEL PROJECTS: TECHNICAL OVERVIEW CONTENTS HALFEN Products: Page 39 PRODUCTS SUMMARY Page ABOUT HALFEN References / Projects Page 60 HALFEN Product Range Page 61 HALFEN International Page 62 Contact Page 63 Title: tomjasny.com 3

4 HALFEN Applications APPLICATION IN RAIL TUNNELS In this example the rail tunnel was designed using tubbing segments. Most of the HALFEN solutions illustrated here are also suitable for use in cast-on-site concrete elements. HALFEN CHANNELS Fixing of building components to concrete elements Overhead cantenary systems Door fixings / emergency, cross passage doors Access walkways Hand rails/safety barriers Utility and service installations Signalling equipment Signage Page 40 HTA-CE 40/22 HTA-CS Curved cast-in channel HTA-CE Cast-in channel HALFEN TRANSPORT ANCHOR SYSTEMS Transport and lifting of precast concrete elements Tubbing segments Ballastless tracks Façade elements Base segment Page 58 C E HALFEN HD 2.5 HD Sleeve anchor system KKT Anchor system Anchoring systems HALFEN Channels and HALFEN Bolts make up a system HALFEN special bolts are suitable for all HALFEN Channels: quick and simple installation of components without drilling subsequent installation or fixing of further components is always possible temporary fixings during construction HS HALFEN Bolt with nut HZS Bolt, serrated Framing technology HSR Bolt, nibbed 4

5 HALFEN FRAMING CHANNELS Post-install fixings for maintenance Upgrade of technical equipment and production facilities Applications as for cast-in channels Page 44 HALFEN Framing channels, straight and curved FLEXIBLE FRAMING SYSTEM Quick installation in tunnels Heavy pipe systems (for example, emergency water supply, drainage pipes) Heavy cables (for example, electrical power cables) Page 48 kg HALFEN HTA-CS Curved Solution: Applications in section HALFEN POWERCLICK System HALFEN BRACKETS Supports for: Heavy pipe systems (for example, emergency water supply, drainage pipes) Heavy cables (for example, electrical power cables) Access paths Page 49 Page 41 Section: Rail tunnel with cross passage door, HTA-CS Curved channel HALFEN Bracket including end cap 5

6 HALFEN PROJECT Lötschberg Base Tunnel, Switzerland Cast-on-site concrete, inner tunnel lining Elkuch Bator AG, Switzerland, 6

7 HALFEN Products: Anchoring systems HALFEN HTA-CE CAST-IN CHANNELS THE INTELLIGENT ALTERNATIVE TO DRILLING AND WELDING HTA-CE Standard HALFEN Cast-in channels HALFEN Cast-in channels are the ideal basis for easy-to-assemble, adjustable fixings. Filler strips prevent the concrete seeping into the channel. Numerous types of secondary components can be connected or fixed to the HALFEN Cast-in channels. APPLICATIONS: fixing of cross passage doors fixing of systems subjected to dynamic loads Lötschberg and Gotthard Base Tunnel Switzerland The Lötschberg and Gotthard transit axes are at the heart of Europe s most important freight corridor, connecting Rotterdam (Netherlands) and Genoa (Italy); the so-called Rhine-Alps corridor. The Lötschberg base tunnel has a length of 34.6 km and has 174 cross passage doors. The connections through the cross passage doors are typically used as escape routes. The total length of the Gotthard Base Tunnel is 57 km (currently the longest tunnel in the world), it consists of two single-track tunnels with 350 sliding cross passage doors. European Technical Approval ETA - 09/ CPD European Technical Assessment ETA -16/ CPR The cross passage doors are fixed to hot-rolled HALFEN Castin channels. The doors are subjected to fatigue related stresses caused by passing trains; these stresses in particular can be effectively absorbed by the hot-rolled channels. Further Information Please refer to our Technical Product Information to find out more about HALFEN HTA-CE Cast-in channels. Elkuch Bator AG, Switzerland, Elkuch Bator AG, Switzerland, Cross passage door, closed, Lötschberg Base Tunnel Installed sliding cross passage door, Gotthard Base Tunnel 7

8 HALFEN PROJECT Shenzen Metro Line, China Tunnel boring machine (TBM) in use 8

9 HALFEN Products: Anchoring systems HZA DYNAGRIP SERRATED HALFEN CHANNELS HZA DYNAGRIP Serrated HALFEN Cast-in channels The serration in the channels ensures positive locking anchorage in the longitudinal direction of the channel, even at high loads. APPLICATION: fixing overhead cantenary systems fixing various equipment fixings subjected to dynamic loads Shenzen Metro Line 9 Shenzen, China Line 9 of the Shenzhen Metro has an overall length of approximately 25 km. The Metro starts in Hongshu Bay and ends in Wenjin, with 22 stations along the route. The Shenzen Metro is one of many metro projects in which the advantages of HALFEN Cast-in channels are applied. In each tubbing-ring segment of the tunnel 16 metres of cast-in channels were installed to form a channel ring, to which the technical equipment, including the electrical conductor rail, was attached. Safe and reliable. Quick and economical. y x z Serrated 3D loads Suitable for dynamic loads officially App. No Z approved Hot-rolled, serrated cast-in channels were selected for this project as they meet all the requirements for loads in all directions, are suitable for dynamic loads and seismic loads and also fulfil the fire and corrosion protection requirements. Further information Please refer to our Technical Product Information to find out more about serrated HALFEN Channels. HALFEN HZA 29/20 Channels cast into tubbing segments Underwater storage of tubbing segments 9

10 HALFEN PROJECT Finnetunnel, Germany Tunnel constructed using precast tubbing segments with service equipment installed Tunnel constructed using precast tubbing segments with service equipment installed 10

11 HALFEN Products: Anchoring systems HTA-CS HALFEN CURVED CAST-IN CHANNELS HTA-CS Curved Solution As soon as building projects include curves, object specific specifications arise for any required components. In these cases HALFEN Cast-in channels can usually be curved according to demand. Curved channels can be manufactured as individual segments or, if requested, as complete rings. Finnetunnel Finne (Saxony-Anhalt), Germany Completed at the end of 2011, the newly constructed Deutsche Bahn AG (German railway company) Erfurt-Leipzig/ Halle line is part of the high-speed Berlin to Munich link, which in turn is part of the Trans-European rail network. The new rail link has been designed for a maximum speed of 300 km/h. APPLICATION: fixing overhead cantenary systems fixing various equipment fixings subjected to dynamic loads Anchor channel for line feeder Anchor channel for return conductor R 4700 S0 Tunnel axis Track centre Sample custom project: Support provided by HALFEN Anchor channel for wheel tensioners Anchor channel for catenary wires, etc. Anchor channel for fixed point anchor Anchor channel for tension load Approximately 48,000 tubbing segments were required for the tunnel length of approximately 6.9 km. Using cast-in channels eliminated the need to post-install a fixing system in the tunnel. Subsequently, all that was required was to install the actual service and operating systems. Further information Please refer to our Technical Product Information to find out more about curved HALFEN Cast-in channels. Storage of tubbing segments with cast-in HALFEN Channels HALFEN HTA-CS 52/34 Curved cast-in channels, as delivered 11

12 HALFEN PROJECT Albaufstieg Alb ascend tunnels Stuttgart to Ulm, Germany Tunnel in tubbing construction method during construction 12

13 HALFEN Products: Anchoring systems ACCESSORIES FOR HALFEN CAST-IN CHANNELS: HALFEN FIXING CONE HFK Fixing cone The System includes: Plastic bolt with A4 washer plastic bolt with design breaking point as failure element in the installation system Fixing cone with spanner flats precise positioning of cast-in channels using fixing cones Stuttgart Ulm Rail project PFA 2.2 Albaufstieg, Alb ascend railroad access to the ALB region of Germany In the Stuttgart to Ulm rail project, the construction of the Alb ascend tunnels was managed by a consortium of companies; these included PORR, G. Hinteregger, ÖSTU-STETTIN and SWIETELSKY. The Alb ascend consists of the Bosslertunnel (tubbing segment construction) and the Steinbühltunnel (on-site concrete construction), each of which is designed as two single-track tunnels. To provide a secure fixing for the overhead catenary system HALFEN Cast-in channels were cast into the concrete of both tunnels. HALFEN Fixing cones were used to ensure precise positioning of the HALFEN Cast-in channels to the steel formwork during production of the tubbing segments, resulting in significant time savings. Once the concrete has cured, the tubbing segment is simply lifted out of the formwork as the plastic screw has a design breaking point; the cone remains fixed to the formwork for further use, if required. M12 Sealing plugs for sealing drill holes in steel formwork; this allows the same formwork to be used to cast tubbing segments with or without cast-in channels. APPLICATION: for simple, quick and adjustable fixing of cast-in channels to steel formwork suitable for easy accessibility for installation solely from above the formwork Further information Please refer to our Technical Product Information to find out more about our accessories for HALFEN Channels. Source: Herrenknecht Formwork Fixing HALFEN Cast-in channels to the formwork for a tubbing segment using HFK Fixing cones Lifting a tubbing segment at a precast production plant 13

14 HALFEN PROJECT Allegheny North Shore Connector Tunnel Pittsburgh/USA Tubbing segment built tunnel with utilities system installed 14

15 HALFEN Products: Framing technology HALFEN FRAMING CHANNELS FLEXIBLE BOLT CONNECTIONS HALFEN Framing channels HALFEN Framing channels together with the corresponding HALFEN Bolts (alternatively threaded plates) have all the advantages required of adaptable bolt connections and framing structures. The system s flexibility means the most economical solution can be selected for the specified requirements. APPLICATION: fixing service and drainage pipes fixing firefighting equipment Allegheny North Shore Connector Tunnel Pittsburgh, United States of America The Allegheny North Shore Connector tunnel is part of a 1.9 kilometer extension of the 40 kilometer long, urban rail link in Pittsburgh, Pennsylvania. The tunnel under the Allegheny River connects downtown Pittsburgh to the north shore region of the city. This regional investment will significantly improve the potential for development in the Pittsburgh region. In addition, the tunnel is part of the transformation of Pittsburgh s automobile orientated infrastructure to a public transport orientated system. HALFEN Curved cast-in channels were installed to the precast segments in the tunnel. This provided a cost effective system for fixing heavy operating and service utilities, including firefighting equipment. Light duty support system HM 36/36 with HS 38/17 Medium duty support system HM 41/41 with HZS 41/41 Further information Please refer to our Technical Product Information to find out more about HALFEN Framing channel systems. Heavy duty support system HM 72/48 with HS 72/ Fixing of pipe supports to galvanized, hot-rolled HM Channels using HSR nibbed bolts Fixing of pipe systems 15

16 HALFEN PROJECT Brenner Base Tunnel, Austria Installing base elements in an exploratory tunnel BBT SE 16

17 HALFEN Products: Transport anchor systems DEHA SPHERICAL HEAD ANCHOR WITH UNIVERSAL HEAD LIFTING CLUTCH HALFEN Transport anchor systems HALFEN Transport anchor systems are used when precast concrete elements need to be moved precisely and safely. A single transport anchor system consists of an anchor cast in the concrete element, a recess former and a load lifting clutch. The two components of a system are quickly connected for transport, either by simply screwing the respective lifting clutch into the anchor, or with the easy-to-attach universal head lifting clutch. APPLICATION: tubbing segments base segment slabs ballastless tracks façade elements Brenner Base Tunnel (BBT) Los Tulfes-Pfons, Exploratory tunnel, Ahrental-Pfons Innsbruck, Austria The Brenner Base Tunnel consists of two main tunnels, an east and a west tunnel, with a lower exploratory tunnel underneath. The tunnel project with a total length of 55 km, connects Innsbruck in Austria to Franzenfeste/Fortezza in Italy quick safe simple A branch tunnel to Tulfes on the Austrian side of the tunnel will result in a total length of 64 km after completion, making the BBT the longest tunnel in the world. In the Ahrental-Pfons exploratory tunnel the base element is designed as a drainage channel to drain mountain water, and is covered with a slab. Using KKT Spherical head anchors in this project to lift, transport and install the prefab ricated cover slabs proved very time and cost effective. Further information Please refer to our Technical Product Information to find out more about DEHA Spherical head lifting systems. Cover slab; each slab has four cast-in KKT Spherical head transport anchor points Cross section showing the base segment in detail with cover slab in place 17

18 HALFEN PROJECT Antwerp North-South Link (ASDAM), Belgium Single track rail tunnel during construction 18

19 HALFEN Products: Framing technology HALFEN FRAMING CHANNELS FOR SPECIAL DEMANDS Framing channels: Curved and weldable Hot-rolled framing channels are particularly suitable for heavy loads, dynamic loads, and if weldability is an issue. This ensures that special customer specifications can also be realized to ultimately attain quick and efficient assembly at the construction site. North-South Link (ASDAM) Antwerp, Belgium This rail tunnel runs under the centre of Antwerp and consists of two single-track tunnels and was constructed using the tubbing segment method (7 segments plus 1 capstone with a thickness of 35 cm). The total length of the high-speed line is 2.5 km and the diameter of the tunnel is 8.27 m. Special framing channels were produced for the permanent fixings for the tunnel service equipment. These framing channels were fitted where the screw connections in the transverse joints of the tubbing segments are normally located. Steel flanges with an appropriate bolt hole were welded onto the back of the curved framing channels. This allowed the channels to be fixed into the pockets of the prefabricated tubbing segments that are necessary for the fixing bolts to secure the individual tunnel elements. APPLICATION: for retrofit connections installing technical and service equipment high loads dynamic loads Hot-rolled HALFEN HM 72/48 Channel steel flange with predrilled bolt hole welded to back This solution was used in two further tunnels in Belgium: the Diabolo tunnel (approx. 2 km long), for the north rail link to Brussels Airport (finished in 2012), and the Liefkenshoek Rail Link (approx. 6 km long) for crossing under the river Schelde and the canal dock, which entered service at the end of Further information Please refer to our Technical Product Information to find out more about HALFEN Framing systems. HM 72/48 Framing channel bolted to transverse joint Tunnel wall with additional fire protection layer between the framing channels

20 HALFEN Application APPLICATION IN UTILITY TUNNELS In this example the utility tunnel was designed using tubbing segments. Most of the HALFEN solutions illustrated here are also suitable for use in cast-on-site concrete elements. HALFEN FRAMING CHANNELS Subsequent installations in upgrade and repair projects Expansion or upgrade of technical equipment and production facilities Applications as for cast-in channels Page 44 HALFEN Framing channels, straight and curved HALFEN TRANSPORT ANCHORS Transport and lifting of precast elements Tubbing segments Base slabs Page 58 C E HALFEN HD 2.5 HD Sleeve anchor system KKT Anchor system Anchoring systems HALFEN Channels and HALFEN Bolts HALFEN special bolts are suitable for all HALFEN Channels: quick and simple installation of components without drilling subsequent installation or fixing of further components is always possible temporary fixings during construction HS HALFEN Bolt with nut make up a system HZS Bolt, serrated Framing technology HSR Bolt, nibbed 20

21 HALFEN CAST-IN CHANNELS As a channel ring or channel segment for fixing suspended crane runway systems Cable and pipe installations Access paths Post and beam systems Page 40 HTA-CE 40/22 HTA-CS Curved cast-in channel HTA-CE Cast-in channel FLEXIBLE FRAMING SYSTEM Quick installations in tunnels Heavy pipe systems (for example: emergency water supply, drainage pipes) Heavy cables (for example: electrical power cables) Page 48 kg HALFEN Powerclick system HALFEN BRACKETS support for: Heavy pipe systems (for example: emergency water supply, drainage pipes) Heavy cables (for example: electrical power cables) Access paths Page 49 Cast in channels and Drill and dowel framing channels HALFEN Brackets Fexible framing systems HALFEN Bracket including end cap 21

22 HALFEN PROJECT Lausward Power Station, Germany Culvert, constructed using precast pipe segments Planer Ingenieurbuero-Wendt 22

23 HALFEN Products: Framing technology HALFEN FRAMING CHANNELS SYSTEM THE FLEXIBLE FRAMING SYSTEM POWERCLICK Framing system Projects of all sizes and for all load types are possible with just a few different components. Using Powerclick in your projects significantly reduces planning and assembly time. The twelve types of multifunctional connection elements are delivered pre-assembled with quick assembly bolts, and are easily installed using basic tools. APPLICATION: service and utility pipes cable trays Lausward Power Station Düsseldorf, Germany The world s most efficient steam turbine power station to date is located in Düsseldorf, Germany. With a production output of 600 Megawatts electricity and 300 MW district heating, the power station achieves an efficiency of 85 %. The core of the system is a pipeline infrastructure made of high-performance reinforced concrete pipes. The walk-through culvert that supplies the district heating runs under the river Rhine and has been designed to accommodate 21 pipelines. The client insisted on installation without requiring drilling to retain the high quality of the pipes. In this case, two serrated cast-in channels were installed to form a ring. The Powerclick Framing system was fixed to the channel ring to provide an adaptable flexible support. Application example; POWERCLICK Further information Please refer to our Technical Product Information to find out more about the HALFEN Powerclick system. kg Reinforcement cage on steel formwork with serrated HALFEN channels Prefabricated pipe segments with cast-in channels 23

24 HALFEN PROJECT Turtmann Tunnel, Switzerland Tension ring solution with GFRP plastic piping 24

25 HALFEN Products: Framing technology HALFEN FRAMING CHANNELS SYSTEM FLEXIBLE FRAMING SYSTEM HALFEN Brackets and connection elements The flexible HALFEN Framing channels are used for the quick assembly of support structures. Pre-assembled components ensure quick and easy assembly, even for challenging project conditions. The flexible bolt connections allow construction tolerances to be compensated for on-site. Utilities for the Martischejiu service station; A9 road tunnel Turtmann project, Switzerland The Turtmann Tunnel project with a total length of 1350 m also required utilities supply pipes. In this case, service utilities comprising of DN 2000 plastic pipes for drainage, hydrant supply pipes and electrical power lines for the Martischejiu service station. APPLICATION: service and utility pipes cable trays Hinged beam HM 52/34 Hexagon bolt with nut Hinged cantilever With a post-installed channel system (designed as a tension ring) and a quick install system (pre-assembled parts), all utility pipes and cables could be fitted quickly and safely. Framing channels are not only designed to be attached or dowelled to concrete components. They are also suitable for use on surfaces made of other materials, for example: metals, GFRP (carbon fibre reinforced plastic). They can be braced against the tunnel wall, or also bolted into tubbing segment tunnels. HVT 52-6 Tension bolt HVT 52-7 Further information Please refer to our Technical Product Information to find out more about the flexible HALFEN Framing systems. Hinged brace HM 52/34 Round utility tunnel; service station, Switzerland Application: Powerclick System Sewer pipe support using brackets with pre-assembled fixings 25

26 HALFEN PROJECT Bewag Tunnel (Berlin), Germany Utility tunnel with 380 kv power cables 26

27 HALFEN Products: Anchoring systems HALFEN CHANNELS SUBJECTED TO FIRE Designed for fire resistance The design of anchorages for fire load must take into account the requirements of Technical Report TR 020 Assessment of anchorages in concrete with regard to fire resistance. The corresponding characteristic values can be found in the annex of ETA-09/0339 and ETA-16/0453. Bewag tunnel Berlin, Germany To connect three substations, Mitte, Friedrichshain and Marzahn in the city centre to the 380 kv high-voltage grid, a total of 11.5 km of cable tunnel was built approximately 25 to 30 m below ground. The tubbing segment section on its own has a length of 8.5 km (about 40,000 elements); the tunnel section with concrete pipes is 2.9 km. The outer diameter of the tunnel is approximately 3.6 m and the inner diameter 3.0 m. To support the six 380 kv cables, HALFEN HTA 52/34 Cast-in channels were cast into the tubbing segments and the reinforced concrete pipes in the precast concrete plant. In addition to the power cables, HALFEN Cast-in channels were also used to attach the tunnel lights, the support channels, the overhead rail service car and the cable trays. APPLICATION: reinforced components, for example: wall slabs, ceiling slabs, beams, columns fire resistance; up to R120 fire exposure on one or more sides high dynamic and static point loads, e. g. caused by the attachment of overhead rail service cars or heavy power cables Temperature in [ C] 1,200 1, Standard time temperature curve Time in [min] Temperature of the STTC during tests Further information Please refer to our Technical Product Information to find out more about HALFEN Cast-in channels. Power grid BERLIN Lubmin Wolmirstedt Malchow 220 kv Overhead power lines 380 kv Overhead power lines 380 kv Underground cable system 110 kv Grid Transformer station Neuenhagen Reuter 1 Reuter 2 Friedrichshain Mitte 1 Mitte 2 Wulheide Transformer station Thyrow Reuter 1 Reuter 2 Mitte 1 Mitte 2 Malchow Friedrichshain Wulheide Preilack Overview, 380-kV supply, central distribution/transformer stations via Friedrichshain to Marzahn Overhead rail service car and heavy high power cables 27

28 HALFEN Applications APPLICATION IN ROAD TUNNELS The road tunnel in this illustration was planned using cast-on-site concrete. Most of the HALFEN solutions illustrated here are also suitable for use in tubbing segments. HBT REBEND CONNECTIONS Connection of reinforced concrete elements in: Roofs Floors Walls Page 54 HBT Reinforced connection with approval ACCIDENT RECOVERY SYSTEM For efficient accident recovery and removal of damaged vehicles and other objects. The HALFEN Accident recovery system consists of an anchor plate with ring-bolt, an anti-theft chain and a clutch. Page 59 HALFEN Accident recovery anchor with DEHA Spherical head transport anchor DETAN TENSION ROD SYSTEMS Suspension of ceilings (see example to the right) Suspension of bridges Bracing in support systems Bracing (lattice struts) as tension and compression rod system for suspension of false ceilings or fixing of wall elements Page 57 DETAN is the right choice for suspension of false ceilings: for high steel load capacities for high demands on corrosion and fire prevention/protection for pre-assembled delivery requirements DETAN Tension rod with fork-head and anchor disc 28

29 HDB SHEAR RAILS for increased shear load demands in: Roofs Floors Walls Page 52 HALFEN BRACKETS Support of: Heavy pipe systems (for example, emergency water supply, drainage pipes) Heavy electrical cables Access paths Page 49 HALFEN Bracket including end cap HSC Stud Connector For densely reinforced corbels and frame nodes Page 55 HALFEN HSC-HD HALFEN HSC-S HALFEN FRAMING CHANNELS Retrofit fixings Refurbishment projects Upgrade of technical equipment and production facilities Applications as for cast-in channels MBT REINFORCEMENT COUPLER Retrofitting and upgrades Page 44 Page 56 HALFEN Framing channels, straight and curved HALFEN MBT Standard coupler Cast-in channel HALFEN Accident recovery system MBT Reinforcement coupler HBT Rebend connections HALFEN CHANNELS Cast-in connections Lighting equipment Signalling equipment /signage Hand rails/hand rails Ventilation equipment Wall elements Page 40 Curved HTA-CS cast-in channel HTA 38/17 HTA-CE Cast-in channel 29

30 HALFEN PROJECT Ulricehamn Tunnel, Sweden Fair-face concrete wall elements inside the tunnel Vijay C / SE360 30

31 HALFEN Products: Rod systems DETAN ROD SYSTEMS EFFICIENT STRUCTURAL BRACING DETAN Rod systems The DETAN Rod system is suitable for tensile and compressive loads; with European Technical Approval. The individual components in the DETAN Rod system are available in two finishes: stainless steel or steel. APPLICATION: anchoring of wall elements suspension of ceiling suspension of bridges bracing (in lactice supports) DETAN in the Ulricehamn Tunnel, Sweden The Ulricehamn Tunnel is a 400 m long road tunnel in the south of Sweden. The tunnel is part of the E4/R40 road expansion project between Dållebo and Hester. It has two separate carriageway tunnels, both with two lanes in each direction. The purpose of the expansion is to improve road safety and improve traffic flow along this particular stretch of road. When this section is completed, the entire stretch of road between Stockholm and Gothenburg will be a dual carriageway. HALFEN supplied cast-in channels and the DETAN Rod System to attach the precast concrete elements along the rock wall; a perfect all in one solution with the highest quality standards. Further information Please refer to our Technical Product Information to find out more about DETAN Rod systems. tunnel facing rock reinforcement HTA-CE 52/34 (2 pcs.) threaded rod M16 M30 fork DETAN M30 M30 Vijay C, SE360 hex-nut M30 coupler M30 angle profile View of the tunnel approach, i. e. exit Anchoring the tunnel wall elements using DETAN Tension rods 31

32 HALFEN PROJECT Horental Road Tunnel, Switzerland Formwork carriage 32

33 HALFEN Products: Reinforcement technology HALFEN HDB SHEAR RAILS SHEAR PUNCHING REINFORCEMENT HALFEN HDB-S Shear rails The HALFEN HDB Shear rails can be used as punching and shear reinforcement. This increases the load-bearing capacity of thin concrete elements. The symmetrical design of the HDB Shear rails guarantees correct installation. APPLICATION: tunnel shell/walls tunnel roofs Uneconomical solution: Complex installation of stirrup cage reinforcement HDB in the Horental Tunnel Küttigen, Switzerland The Horental road tunnel near Küttigen, in Switzerland with a length of approx. 700 m, is part of the new Staffeleggstraße route. The tunnel was constructed using the open trench method (covered tunnel); due to the high horizontal loads expected, a shear reinforcement system was selected. Our solution: Support using HDB-S Shear load reinforcement Traditional stirrup reinforcement is difficult to install because the stirrups have to be shaped and tied during installation. This is not only time-consuming but also inaccurate, resulting in the stirrups often not having sufficient concrete cover. HALFEN HDB-S Dowel rails were used in the tunnel lining to avoid these problems. This ensured speedy and precise installation and also helped to reduce construction time. Further information Please refer to our Technical Product Information to find out more about HALFEN Shear rails. Fixing the HDB element in the reinforcement for the tunnel shell Prepared HDB Element before pouring the concrete 33

34 HALFEN PROJECT Autobahn A1, Cologne Lövenich, Germany Precast girder in the glass roof 34

35 D D HALFEN Products: Reinforcement technology HALFEN HSC STUD CONNECTOR THE EFFECTIVE ANCHOR REINFORCEMENT HALFEN HSC Stud Connector The HALFEN HSC Stud connector is a building authority approved reinforcement optimized for anchorage in concrete. The effective yield of the reinforcement bars is reached with extremely short bond lengths and therefore it is possible to significantly reduce the quantity of steel used. APPLICATION: reinforcement in corbels reinforcement in frame nodes offset supports slabs supports beam supports Noise protection enclosure, Autobahn (Motorway) A1 Cologne Lövenich, Germany The motorway tunnel was planned for a traffic volume of 120,000 vehicles per day and has a length of 1.5 km. The project has two tunnels; these were built without interfering with the flow of the traffic. The steel and glass roof structure is supported on prefabricated, reinforced concrete beams, which in turn are supported on reinforced concrete corbels. This results in very high loads in the reinforced concrete corbels. Using HALFEN HSC Stud connectors during the first construction phase enabled the walls to be cast together with the matching HSC Socket reinforcement bars. The corbels were cast in a second phase. Here the HSC Connector rods were screwed into the sockets as tensile reinforcement; this ensures a 100 percent positive tensile-load transfer. HSC 20 Application example; HALFEN HSC elements in a concrete corbel Further information Please refer to our Technical Product Information to find out more about the HALFEN HSC Stud Connector. HSC 20 Using HSC elements to post-installed reinforced concrete corbels Supporting the prefabricated beams on the reinforced concrete corbels 35

36 HALFEN PROJECT A1 Motorway, Cologne Lövenich, Germany Aerial view of the noise protection enclosure Photo: Knut Laubner, Bonn, Germany 36

37 HALFEN Products: Material properties CORROSION RESISTANT HALFEN ANCHORING SYSTEMS Corrosion protection Stainless Steel A4 and HCR Chromium is the most important alloy element used in stainless steels. A specific amount of chromium content causes a passivation layer to be formed on the surface of steel, therefore protecting the base material from corrosion. This is why stainless steels have high corrosion resistance. FV = HDG = Hot-dip galvanized During the hot-dip galvanizing process, HALFEN Channels are immersed in molten zinc (immersion process), with a temperature of approximately 460 C. During this process the zinc alloys with the steel to form a protective layer on the steel, which increases the corrosion resistance. Noise protection enclosure, Autobahn (Motorway) A1 Cologne Lövenich, Germany The noise protection enclosure was designed in accordance with the required guidelines for equipment and the operation of road tunnels (RABT Richtlinien für die Ausstattung und den Betrieb von Straßentunneln) and additional technical contract specifications for engineering projects (ZTV-ING zusätzliche technische Vertragsbedingungen für Ingenieurbauten). The material specification for fastening the ventilation units specified (HCR) High Corrosion Resistant steel. APPLICATION: very high corrosion demands: HCR = High Corrosion Resistance Material medium corrosion demands: A4 Material enclosed and dry areas: FV (HDG) = Hot-dipped material with 50 μm STAINLESS STEEL HALFEN Cast-in channels in stainless steel HCR Channels in HCR (High Corrosion Resistance) materials, such as the HALFEN Cast-in channels, are mandatory in environments with expected concentrations of chlorides, sulphur and nitrogen oxides; this is also the case in Germany. Further information Please refer to our Technical Product Information to find out more about HALFEN HTA-CE Cast-in channels. HZM 38/23 channels in A4 steel used to attach the support structure of the steel roof to the top of the precast concrete roof beams HTA 38/17 in HCR as attachment point for the ventilation units fixed to the precast concrete roof beams 37

38 2017 HALFEN Applications in Tunnel projects

39 Technical information by product Contents HALFEN PRODUCTS TECHNICAL OVERVIEW HALFEN PRODUCTS IN TUNNEL PROJECTS HALFEN HTA-CE CHANNELS Hot-rolled HALFEN Cast-in channels Page 40 Cold-rolled HALFEN Cast-in channels Page 41 HALFEN HZA CHANNELS Hot-rolled and cold-rolled Cast-in channels Page 42 HALFEN HZA-PS CHANNELS For increased safety-relevant applications Page 43 FRAMING CHANNELS HALFEN HM, HZM, HL and HZL Framing channels Page 44 Heavy duty support system Page 45 Medium duty support system Page 46 Light duty support system Page 47 HALFEN POWERCLICK Framing channel systems Page 48 HALFEN Corbels Page 49 HALFEN Flexible serrated corbels Page 50 HALFEN BOLTS For all anchor and framing channel systems Page 51 REINFORCEMENT SYSTEMS HALFEN HDB Shear reinforcement Page 52 HALFEN HBS-05 Screw connections Page 53 HALFEN HBT Rebend connections Page 54 HALFEN HSC Stud connector Page 55 HALFEN MBT Reinforcement couplers Page 56 ROD SYSTEMS DETAN Rod systems Page 57 TRANSPORT ANCHOR SYSTEMS Screw-in transport anchor/quick-clutch system Page 58 HALFEN Accident recovery anchor Page 59 ABOUT HALFEN References / Projects Page 60 HALFEN Product overview Page 61 HALFEN International Page 62 Contacts Page 63 39

40 HALFEN HTA-CE Channels Hot-rolled HALFEN Cast-in channels HTA-CE ANCHOR CHANNELS In addition to excellent adjustability, HALFEN Cast-in channels save considerable installation time. The result: faster overall construction and therefore increased cost saving. The channels are designed for high loads, for fixing in cracked and non-cracked concrete, for small edge distances, and for noise and dust free installation. The channels have a high corrosion resistant coating, are suitable for dynamic loads and also fulfil fire prevention requirements. Further special quality features are regulated in approvals ETA-09/0339 and ETA-16/0453. hot-rolled channel suitable for dynamic loads NEW: HTA-CE 50/30P and HTA-CE 40/22P P = Plus for extra load capacity. NEW! PARAMETERS HTA-CE (HOT-ROLLED) Channel type HTA-CE 72/48 HTA-CE 55/42 HTA-CE 52/34 HTA-CE 50/30P HTA-CE 50/30 HTA-CE 40/22P HTA-CE 40/22 Hot-rolled HALFEN HTA-CE Channels Material Bolts HS 72/48 HS 50/30 HS 50/30 HS 50/30 HS 50/30 HS 40/22 HS 40/22 Thread M 20 M 30 M10 M24 M10 M20 M10 M20 M10 M20 M10 M16 M10 M16 N Rd [kn] / V Rd [kn] 55.6 / / / / / / / 14.4 Approved for fatigue relevant tensile stress/ steel * * Reliable and safe no damage to load-bearing reinforcement suitable for components with fire prevention requirements suitable for installation in concrete compression and tension zone high corrosion resistant steels available (for cold-formed channels only) dynamic loadable hot-rolled profiles with (ETA) European Technical Approval/Assessments reliable calculation using HALFEN Software Quick and economical adjustable anchorage bolts instead of welding maximum cost-effectiveness when installing bolts in rows cost-effective installation using simple tools effective pre-planning results in shorter construction time wide range of products for various requirements health and safety friendly due to vibration and noise free installation 40

41 DECLARATION OF PERFORMANCE CONF- DOP_HTA 02/16- E HALFEN Anchor channel HTA / Special screw HS No. H01-09/ Unique identification code of the HALFEN Anchor channel HTA / HALFEN Special bolt HS product - type Type, batch or serial number or any other element allowing identification of the construction product as See ETA- 13/0339, Annex 1, 2, 4 and 5 required pursuant to Article 11(4) Intended use or uses of the construction product, in accordance with the applicable harmonized technical specification, as foreseen by the manufacturer: Cast- in, C- shaped, hot - rolled or cold - formed anchor channel Generic type and use with at least 2 metal anchors fixed on the profile back in combination with hammerhead or special nib bolts 28/15 with HS 28/15 M6- M12, 38/17 with HS 38/17 M10- M16, Product size covered 40/22 and 40/25 with HS 40/22 M10- M16, (anchor channels and corresponding screws) 50/30, 49/30, 52/34 and 54/33 with HS 50/30 M10 - M20, 55/42 with HS 50/30 M10-M24 72/48 and 72/49 with HS 72/48 M20-M30 Cracked and non - cracked concrete C12/15 to C90/105 according For use in EN 206-1: Hot- dip galv. steel / electroplated steel for dry internal conditions Hot- dip galv. steel / hot - dip galv. steel or electroplated steel with special coating also for internal conditions with normal Anchor material / Screw material humidity and intended use Stainless steel / stainless steel also f or medium corrosion exposure High corrosion resistant steel / high corrosion resistant steel also for high corrosion exposure Static & quasi static tension and shear loads perpendicular to the Loading longitudinal channel axis. Fire exposure, fatigue tension loads for specific profiles Name, registered trade name or registered trade mark and contact address of the manufacturer as required HALFEN GmbH, Liebigstraße 14, Langenfeld, Germany pursuant to Article 11(5) Where applicable, name and contact address of the authorized representative whose mandate covers the - tasks specified in Article 12(2) System or systems of assessment and verification of constancy of performance of the construction product as System 1 set out in Annex V In case of the declaration of performance concerning a - construction product covered by a harmonised standard Deutsches Institut für Bautechnik (DIBt) issued ETA - 09/0339 on the basis of CUAP 06.01/01, Version Dec. 2010, the notified body 0432 performed under system 1 In case of the declaration of performance concerning a (i) Determination of the product type on the basis of type testing construction product for which a European Technical (including sample - testing), typ e calculation, tabulated values or Assessment has been issued descriptive documentation of the product; (ii) Initial inspection of the manufacturing plant and of factory production control; (iii) Continuous surveillance, assessment and evaluation of HALFEN HTA-CE Channels Cold-rolled HALFEN Cast-in channels CE marking The CE in the name of this product signifies that the channel is CE compliant. By identifying its products in this way HALFEN as the manufacturer declares that it is responsible for the conformity of the product with its DoP (Declaration of performance), and that the specified performance and compliance with all relevant European legislation has been applied. Product range In addition to the standard version, curved HTA-CS HALFEN Castin channels are also available. Produced to customer specifications this type of channel avoids time consuming on-site modifications; drilling or thread cutting in installed, corrosion protected components is no longer required. PARAMETERS HTA-CE (COLD-ROLLED) Channel type HTA-CE 72/49 HTA-CE 54/33 HTA-CE 49/30 HTA-CE 40/25 HTA-CE 38/17 HTA-CE 28/15 Hot-rolled HALFEN HTA-CE Channels Material Bolts HS 72/48 HS 50/30 HS 50/30 HS 40/22 HS 38/17 HS 28/15 Thread M20 M30 M10 M20 M10 M20 M10 M16 M10 M16 M6 M12 N Rd [kn] / V Rd [kn] 55.6 / / / / / / 5.0 A4 = Stainless steel FV = Steel hot-dip galvanized Further information Please find the Declaration of Performance DoP and more Product information about HALFEN HTA-CE Cast-in channels on our website. 41

42 HALFEN HZA Cast-in channels Hot-rolled and cold-rolled cast-in channels SERRATED HZA CAST-IN CHANNELS AND HZA DYNAGRIP HALFEN HZA Cast-in channels are a further development for applications where high loads in the longitudinal direction of the channel also can be considered. y z x serrated 3D Loads The special serration guarantees positive-locking load transfer. In addition, HZA DYNAGRIP HALFEN Cast-in channels can safely absorb fatigue relevant stress amplitudes up to 15.0 kn with a load cycle of N = and therefore meet all requirements for reliable fixings as required for crane runways or for securing cross passage doors against suction caused by passing trains. officially App. No Z approved hot-rolled channel profile suitable for dynamic loads officially App. No Z approved Z PARAMETERS HZA AND HZA DYNAGRIP Channel type HZA 64/44 DYNAGRIP HZA 53/34 DYNAGRIP HZA 38/23 DYNAGRIP HZA 29/20 DYNAGRIP HZA 41/22 Hot-rolled Cold-rolled HALFEN HZA Channels Material Bolts HZS 64/44 HZS 53/34 HZS 38/23 HZS 29/20 HZS 41/22 Thread M20 M24 M16 M20 M12 M16 M12 M12 M16 N Rd [kn] / V Rd [kn] 37.8 kn All load directions 30.8 kn All load directions 16.8 kn All load directions 11.2 kn All load directions 7.0 kn All load directions Approved for fatigue relevant tensile stress A4 = Stainless steel FV = Steel hot-dip galvanized * = A4: on request 42

43 HALFEN HZA-PS Cast-in channels Channels for maximum safety relevant applications HOT-ROLLED HZA-PS CAST-IN CHANNELS PS = PowerSolution This HALFEN Cast-in channel is suitable for special application in safety-relevant areas subjected to internal or external load effects, for example in nuclear power plants. All tests, which were carried out at the Technical University of Dortmund in Germany, were conducted in concrete with crack widths fluctuating by 1.0 mm up to 1.5 mm. The results were summarized in evaluation report no E. y z x serrated 3D Loads suitable for dynamic loads suitable for seismic loads caused for example by earth-quakes suitable for use in safety-relevant areas in nuclear power plants or other nuclear facilities PARAMETERS HZA-PS: ACCORDING TO EVALUATION REPORT TU DORTMUND Channel type HZA-PS 64/44 DYNAGRIP HZA-PS 53/34 DYNAGRIP HZA-PS 38/23 DYNAGRIP HZA-PS 29/20 DYNAGRIP Hot-rolled HALFEN HZA-PS Channels Material Bolts HZS 64/44 HZS 53/34 HZS 38/23 HZS 29/20 Thread M20 M24 M16 M20 M12 M16 M12 N Rd [kn] / V Rd [kn] 37.8 kn All load directions 30.8 kn All load directions 16.8 kn All load directions 11.2 kn All load directions Approved for fatigue relevant tensile stress A4 = Stainless steel FV = Steel hot-dip galvanized * = A4: on request 43

44 Framing channels HALFEN HM, HZM, HL and HZL Framing channels HALFEN FRAMING CHANNEL SYSTEMS AND FLEXIBLE BOLT CONNECTIONS The flexible HALFEN Channel bolt system is an all-in-one support and fixing system. Advantages fully flexible positioning and dimensioning of the bolt connection flexible selection of corrosion protection: a) strip-galvanized channels for standard corrosion protection b) hot-dip galvanized channels for high corrosion protection c) stainless steel channels (A2, A4, HCR) for maximum corrosion protection allows quick assembly and adjustment of the overall system and individual components simple modification or upgrade of a whole system without requiring machining no specialists required for on-site installation and modification on-site installation and modification are dust and noise free bolting does not damage the corrosion protection of system components a wide selection of standard channels with very high load-bearing capacities Hot-rolled framing channels HM Smooth channels HZM Serrated channel Hot-rolled framing channels are exceptionally suitable for: large loads dynamic stress welding HM Smooth channel very high tensile loads can be transmitted loads in the longitudinal direction are also possible when using a HSR nib bolt (only for mild steel) HZM Serrated channel the serration allows high longitudinal loads economic with a selection of five channel sizes Cold-rolled framing channels Cold-rolled channels are a cost effective solution for lower loads. These are available in slotted or non-slotted versions. HM, HL Smooth channels HM, HL Smooth channels larger product range; therefore very economic HZL, HZM Serrated channels HZL, HZM Serrated channels for loads in the channel longitudinal direction slippage-safe connection for large channel loads 44

45 Framing channels Heavy duty support system HALFEN FRAMING CHANNELS HEAVY DUTY SUPPORT SYSTEM LOAD CAPACITIES HEAVY DUTY SUPPORT SYSTEM Channel type HM 72/48 HM 55/42 HM 52/34 HM 50/30 HM 49/30 Hot-rolled HM 50/40 HL 50/40 Cold-rolled HM 486 Dimensions Framing channels , Material Bolts HS 72/48, HSR 72/48 HS 50/30 HS 50/30, HSR 50/30 HS 50/30 Thread M20 M30 M10 M24 Max. possible point-loadbearing capacity* F z,rd [kn] allow. F z [kn] / *observe bolt load bearing capacity Channel type HM 40/22 HM 40/25 HM 422 HZM 64/44 HZM 53/34 HZM 41/27 HZM 38/23 HZM 29/20 Hot-rolled Cold-rolled Hot-rolled, serrated Dimensions Framing channels Material Bolts HS 40/22, HSR 40/22 HS 40/22 HZS 64/44 HZS 53/34 HZS 38/23 HZS 38/23, HS 38/17 HZS 29/20, HS 28/15 Thread M10 M16 M20 M24 M16 M20 M12 M16 M12 Max. possible point-loadbearing capacity* F z,rd [kn] allow. F z [kn] *observe bolt load bearing capacity FV = Steel hot-dip galvanized A4 = Stainless steel (austenitic structure) HCR = Stainless steel High Corrossion Resistant (austenitic structure) 45

46 Framing channels Medium duty support system HALFEN FRAMING CHANNELS MEDIUM DUTY SUPPORT SYSTEM LOAD CAPACITIES MEDIUM DUTY SUPPORT SYSTEM Channel type HM 41/41, HL 41/41 HZM 41/41, HZL 41/41 HM 41/62, HL 41/62 HM 41/83, HL 41/83 HZL 63/63 HZM 41/22, HZL 41/22 Cold-rolled Dimensions Framing channels Material Bolts HZS/HS 41/41, HZS 41/22 Thread M6 M16 M12 M16 M6 M16 M12 M16 M12 M16 Max. possible point-loadbearing capacity* F z,rd [kn] allow. F z [kn] *observe bolt load bearing capacity Channel type HM 41/22, HL 41/22 Cold-rolled HLL 41/41 HLL 41/22 Dimensions Framing channels Material Bolts HZS/HS 41/41, HZS 41/22 Thread M6 M16 Max. possible point-loadbearing capacity* F z,rd [kn] allow. F z [kn] *observe bolt load bearing capacity FV = Steel hot-dip galvanized SV = Steel sendzimir galvanized A2 = Stainless steel (austenitic structure) A4 = Stainless steel (austenitic structure) HCR = Stainless steel, High Corrossion Resistant (austenitic structure) 46

47 Framing channels Light duty support system HALFEN FRAMING CHANNELS LIGHT DUTY SUPPORT SYSTEM LOAD CAPACITIES LIGHT DUTY SUPPORT SYSTEM Channel type HM 36/36, HL 36/36 HM 38/17 HM 28/28, HL 28/28 HM 26/26, HL 26/26 HM 28/15, HL 28/15 HM 315 HM 20/12, HL 20/12 Cold-rolled Dimensions Framing channels 17,5 Material Bolts HS 38/17 HS 28/15 GWP 28/15 HS 20/12 Thread M10 M16 M6 M12 M5 M10 M6 M8 Max. possible point-loadbearing capacity* F z,rd [kn] allow. F z [kn] *observe bolt load bearing capacity Framing channels and matching HALFEN Bolts 47

48 Framing channels HALFEN POWERCLICK Framing channel HALFEN POWERCLICK FRAMING CHANNELS The POWERCLICK system was developed by HALFEN for industrial pipeline projects. The modular system uses only a small number of multi-functional components to provide hundreds of different support structures. With the POWERCLICK system you have the benefit of safety, efficiency and speed at all stages of a project Product advantages time effective installation minimal number of multi-functional components all required smaller items are delivered preassembled FV = Steel hot-dip galvanized A4 = Stainless steel Faster production start-ups and shorter downtimes Secondary components can be attached to the channels at any location in the system while still remaining fully adjustable Optimum support of pipe loads. Larger pipe diameters are also possible if separate verification is provided Three sizes one system Find the most economical solution quickly with three channel sizes that cover every load level. This allows different pipe diameters to be used in a single system. Three channel sizes one POWERCLICK-Bolt and extensive accessories - compatible with all components... =...make up ONE System: POWERCLICK by HALFEN A4 A4 FV FV FV 48

49 Framing channels HALFEN Brackets a HALFEN Channel product HALFEN BRACKETS HALFEN Brackets are manufactured from standard HALFEN Channels and have the same advantages; fast, reliable and adjustable installation. The brackets are used for the whole support elements. Bolt connections ensure the high-quality corrosion protection coating (hot-dip galvanized or stainless steel) is not damaged during installation. DIMENSIONS AND LOAD CAPACITIES Length L [mm] Brackets 52 Height H [mm] Length L S [mm] KON 52/2 F [kn] F 1 L Length [mm] Brackets 41 KON 41/1 KON 41/D KON 41/2 F [kn] F 1 L Length [mm] Brackets 28/36 KON 28/1 KON 36/1 F [kn] F 1 KON 36/ allow. load 9.0 allow. load 5.35 allow. load F Rd 12.6 F Rd 7.49 F Rd 3.78 allow. load 8.0 allow. load allow. load F Rd 11.2 F Rd F Rd allow. load 7.0 allow. load allow. load F Rd 9.8 F Rd F Rd allow. load 6.0 allow. load allow. load F Rd 8.4 F Rd F Rd allow. load 5.5 allow. load 2.65 allow. load F Rd 7.7 F Rd 3.71 F Rd allow. load 5.0 allow. load All Brackets are available in: 600 F Rd 7.0 F 1 F Rd FV = Steel hot-dip galvanized allow. load 4.5 allow. load 2.10 A4 = Stainless steel 700 F Rd 6.3 L/2 L/2 F Rd 2.95 Fixing using dowels or HALFEN Cast-in channels and HALFEN Bolts L L A combination of HALFEN brackets and bracing plates can be used to absorb loads in the longitudinal direction of a pipe H L S LS All bracket are delivered with end caps Standard HALFEN Channel are used in cantilever brackets; therefore all HALFEN Bolts, connections and accessories can be used for further fixings i Note: All lengths L and heights H listed here refer to our standard elements. Custom solutions are available on request. 49

50 Framing channels HALFEN Flexible serrated cantilever with adjustable bracket HALFEN ADJUSTABLE CANTILEVER The HALFEN flexible cantilever can be pivoted with an angle of ±56. This allows the cantilever to be installed quickly and securely in the correct position even with curved or inclined walls A positive load transfer into the main building component is always guaranteed within the specified angle range of ± 56. The bracket consists of a flexible connection bracket and a HM 41/41 framing channel and is manufactured without requiring welding. The flexible connection bracket (HVT) can also be used separately without a framing channel for the 41 mm system. 56 DIMENSIONS AND LOAD CAPACITIES Length L [mm] F 1 Δ/2 Δ/2 Δ F 2 F 3 F 3 3 x Δ/3 F 4 F 4 F 4 4 x Δ/ F [kn] F 1 F 2 F 3 F 4 allow. load F Rd allow. load F Rd allow. load F Rd All brackets are available in: FV = hot-dip galvanized steel A4 = stainless steel Detail of the serration in the connecting bracket L 109 L Pipe, standard application Pipe, suspended application Freely movable cable tray 50

51 HALFEN Bolts Suitable for all anchor and framing channels HALFEN BOLTS HS, HSR AND HZS HALFEN Channels and HALFEN Bolts are part of a system; When used together they guarantee maximum safety and reliability. HALFEN Bolts HS, smooth suitable for all profiles suitable for loads in all directions identification on bolt tip with one notch HALFEN H Strength class 4.6 / 8.8 galvanized with special coating Chrome (VI)-free (GVs) or hot-dipped (FV) HALFEN H HALFEN A4-70 H 4.6 HALFEN HCR50 H 4.6 Strength class 70 Stainless steel A4 corrosion resistance class III / medium Strength class 50 Stainless steel HCR = high corrosion resistance (1.4529/1.4547) corrosion resistance class V / very high HALFEN HSR Bolt, nibbed only for hot-rolled Profile 40/22P, 50/30P, 52/34, 72/48 only for standard mill finish and hot-dip galvanized steel nibbed bolts; therefore loadable in all directions the hook head design of the bolt prevents unwanted loosing of the bolt under vibration. suitable for loads in longitudinal direction of the channel; according to an expert report indentification on bolt tip with two notches H 8.8 HALFEN Bolt with nib H 8.8 Strength class 4.6 / 8.8 galvanized with special coating Cr (VI)-free (GVs) or hot-dipped (FV) HALFEN HZS Bolt, serrated the serrated channel ensures positive locking even in the longitudinal direction: This eliminates slippage in the connection. indentification on bolt tip with two notches HALFEN A4-70 officially App. No Z approved HALFEN A4-70 HALFEN 8.8 HALFEN FA 70 Strength class 70 Stainless steel A4 corrosion resistance class III / medium Strength class 4.6 / 8.8 galvanized with special coating Cr (VI)-free (GVs) or hot-dipped (FV) Strength class 70 Stainless steel FA = Ferritic Austenitic (Duplex stainless steel, ) corrosion resistance class IV / high Serration 51

52 Reinforcement systems HALFEN HDB as shear or shear punching reinforcement HALFEN HDB SHEAR RAIL THe HDB element consists of a number of doubleheaded studs welded on to a spacer bar. The elements are used as shear and punching reinforcement. System elements are available with short delivery times or custom elements can be made to order on request. HDB-S Shear rail elements are preferred for installation from above after the main top and bottom reinforcement has been installed. It is not necessary to enclose the longitudinal reinforcement and simple visual inspection of the installed elements is guaranteed. PRODUCT CHARACTERISTICS double-headed studs; available with 10 mm to 25 mm diameters custom elements with 2 to 10 double-headed studs individual studs spacing on request for pre-defined reinforcement spacing approved by the DIBt Berlin for all shear stressed components spacers for mm concrete cover available d K d A ONE SYSTEM; FOUR INSTALLATION VARIANTS A SUITABLE SOLUTION FOR EACH APPLICATION HDB/HDB-S Elements the double-headed studs are welded firmly to a spacer bar clip bars can be attached anywhere on the spacer bar to secure the shear rail to the reinforcement HDB/HDB-S System elements available as 2 and 3 anchor elements, can be placed one after another to form a row standard elements with short delivery time 3er 2er HDB-S HDB 2 and 3 anchor elements HDB/HDB-S Custom (pre-assembled) elements from 2 to 10 studs welded to a spacer bar HDB-F Custom elements for precast manufactures from 2 to 8 studs welded to a spacer bar with temporary fixing for semi-precast elements HDB-S with five anchors HDB-F with six anchors 52

53 Reinforcement systems HALFEN HBS-05 Screw connections HALFEN HBS-05 SCREW CONNECTIONS With the HALFEN HBS-05 Screw connection reinforcement connections are made by simply screwing together the appropriate socket and connecting bars. This versatility allows nearly every type of reinforcement connection to be made. HALFEN HBS-05 fulfils national and international calculation standards. Extensive certificates and test reports prove suitability even for extreme loads. The advantages optimal solutions for all types of connections in reinforced concrete elements maximum ductility; HBS-05-Seismic meets the requirements for cyclic alternating loads various types including accessories Scope of delivery The lengths, diameters and materials listed in the table refer to our standard elements. Further types are available on request. Bar loads F sd = kn (d s = depends on the bar diameter). HBS-05-B Socket bar with nailing flange HBS-05-A Connection bar HBS-05-S Socket bar with screw socket d s d s Bar-d s L Thread Bar-d s L Thread Bar-d s L Thread B-12 B-14 B-16 B-20 B-25 B M12 A-12 M12 S M14 A-14 M14 S M16 A M16 S M20 A-20 M20 S M25 2,5 360 M25 2,5 400 M25 2,5 A-25 S special thread 1690 special thread 1730 special thread 400 M28 2,5 360 M28 2,5 400 M28 2,5 A-28 S special thread 1890 special thread 1930 special thread A-32 M32 3 special thread S-32 M12 M14 M16 M20 M32 3 special thread Please state required length L [mm] when ordering or choose standard element. The HBS-05-Box and its main features profiled backing of the steel box provides optimal transfer of shear loads u-shaped box cover made of galvanized sheet steel standard box length: 1250 mm (other lengths on request) HBS-05 Socket bars pre-installed in the HBS-05-Box available with 12 mm/14 mm/16 mm bar diameters Application: cost effective formwork ancillary aid for row installation recess to form a keyed joint for shear loads with sliding formwork 53

54 Reinforcement systems Subsequent concrete connection with HALFEN HBT HALFEN HBT REBEND CONNECTION The HALFEN Rebend connection is used for efficient connection of concrete components which are cast in separate stages and need to be connected. With over 50 combinations of rebar types and box widths, optimum connections are possible for a wide range of applications. The case is made of galvanized sheet steel with a special corrugated backing and a pre-punched hole in the cover, which serves as a handle, allowing easy removal from the case after installation. The anchorage and overlap lengths are verified in accordance with Eurocode 2, taking existing bond conditions into account. general building authority approved and type-tested B500B reinforcing steel ( 8 mm, 10 mm, 12 mm) suitable for both transverse and longitudinal loads with standard case types case back in galvanized and special corrugated sheet steel sturdy, galvanized sheet steel cover with pre-punched hole for easier removal after striking the formwork. single-row and double-row types available three box widths for single-row types; five box widths for double-row types Type 1 Type 2 Type 3 Type 4 Type 5 Type 11 Type 22 Type 23 Type 33 Type 6 Type 7 Type 8 Type 9 Application example: HALFEN HBT as a wall connection HBT Element fitted to a convex / concave curvature Curvature; radius approx m; a smaller radius is achieved with more incisions. Note: For 90 angled reinforcement needs; see also HBS-05 Box. 54

55 Reinforcement systems Tensile reinforcement in corbels with HALFEN HSC HALFEN HSC STUD CONNECTOR The HALFEN HSC Stud Connector is a building authorities approved reinforcement, developed specially for cost effective tensile reinforcement in corbels and frame nodes. The full yield of the reinforcement is already possible with extremely short anchorage lengths. The HALFEN HSC Stud connector is especially beneficial where dense reinforcement occurs such as in corbels and beam to column connections. The problems and resulting costs that occur in conventional layout of reinforcement and the anchorage of bar loads are avoided. The amount of reinforcement steel is considerably reduced and the reinforcement layout is simpler. HSC-S HSC-A HSC-SD HSC-HD HSC-H Product range Dimensions HALFEN HSC Stud Connector Bar Type d s / Length L [mm] Socket bar, single-headed HSC-S - 12 / / / / 230 Connector bar, single-headed HSC-A - 12 / / / / 190 Double socket bar HSC-SD - 12 / / / / 275 Double-headed bar HSC-HD - 12 / / / / 180 Single-headed anchor bar HSC-H - 12 / / / / 190 Please state required length L [mm] when ordering, or select standard element. Application example: HSC-A and HSC-S Accessory products Numerous connection options with the HALFEN HUC Universal connection system: HALFEN HSC-B Steelwork connections HALFEN HSCC Steel corbels HSC-B with steel girder HSC-B with DETAN Connection HSC-B with HSCC Corbel 55

56 HALFEN MBT REINFORCING COUPLER Reinforcement systems Reinforcing coupler for reinforcing steel The HALFEN MBT Reinforcement coupler is a mechanical coupler for B500B reinforcing steel with a diameter of 10 to 40 mm. Form closure to ensure the positive transfer of tension and compression loads in the rebar is achieved by tightening the bolts until the heads break off at the design shear-off point. No preparation of the bars is required: no thread cutting no swaging no crimping MBT Standard coupler PRODUCT ADVANTAGES No welding; only standard tools are required to install HALFEN MBT Reinforcement couplers. DIMENSIONS OF THE MBT STANDARD COUPLER Identification T10* T40* Rebar diameter [mm] Outer diameter socket d [mm] Socket length L [mm] Spanner size [mm] L Number of bolts 4 14 d d s Weight [kg] couplers with these diameters are not included in the approval (Z ). MBT Reduction coupler DIMENSIONS OF THE MBT REDUCTION COUPLER Identification RDZ 16/12* RDZ 40/32* d s1 d 1 Rebar diameter [mm] 16/12 40/32 Outer diameter socket d [mm] Outer diameter socket d2 [mm] Socket length L [mm] L Length a b [mm] d 2 d s2 Spanner size a b [mm] Number of bolts a b Weight [kg] MBT Head coupler DIMENSIONS OF THE MBT HEAD COUPLER Identification EV 10* EV 40* W Rebar diameter [mm] Outer diameter socket d [mm] Socket length L [mm] Total length L o [mm] d d s L Slab thickness t [mm] Slab a a [mm] Spanner size [mm] Number of bolts 2 7 Weight [kg] * listed types are the smallest and largest versions, intermediate sizes on request 56

57 Tension rod systems DETAN Tension Rod system DETAN ROD SYSTEM The DETAN Tension rod system from HALFEN is an innovative product solution that meets safety and quality requirements, and also fulfils the highest aesthetic demands This technically advanced system has a high level of installation ease, can be used for both filigree load-bearing structures as well as in heavy weight construction, and also has European Technical Approval. PRODUCT RANGE Tension and compression rod system in round steel bars with accessories, forkheads, nuts, couplers, anchor discs and cross bracings; in steel and stainless steel. With special system components the system is also suitable for pressure loading. Basis system System variants DETAN Tension Rod or DETAN Compression Rod (not illustrated) Suspension, consisting of a system variant with couplers with lug and a basic system couplers or couplers with lug System variants Cross bracing with cross coupler for cross bracing Anchor disc for cross bracing Fork Threaded plug Sealing set Flat seal Round seal (FV and WB only) Spanner flats System diameter d S Fork end Locking nut Tension rod System length L SYSTEM DETAN-S460, EUROPEAN TECHNICAL APPROVAL ETA-05/0207 System diameter d s [mm] Available minimal system length L [mm] Rod, hot-dipped* Available maximal system length L with one rod [mm] Rod, hot-dipped* *stainless steel version also available on request 57

58 S Transport anchor systems Quick-clutch systems and socket anchors HALFEN TRANSPORT ANCHOR SYSTEM Transport anchors are used in precast concrete building elements to enable safe and easy lifting and transport of the elements to their intended position. HALFEN has four reliable and proven transport anchor systems, which are used depending on the area of application and the type of load lifting equipment available. Each of these systems consists of an anchor which remains in the concrete, a recess former (creates a recess in the concrete and is used to hold the anchor in place during production of the precast element) and a lifting head suitable for the selected anchor. Benefits of using transport anchors and corresponding load lifting equipment; safe and reliable transport and lifting of heavy concrete elements, even at great heights no protruding steel parts due to the use of recess formers exact positioning of the anchors in the building element specified load-bearing capacity for the transport anchors for different boundary conditions and concrete strength workers are protected against incorrect application by dedicated load handling equipment prevents damage / cracks on finished elements durable load handling devices OVERVIEW OF HALFEN TRANSPORT ANCHOR SYSTEMS Transport anchor system KKT DEHA Spherical head anchor system TPA FRIMEDA Transport anchor system HD HALFEN HD Anchor system HA DEHA Socket anchor system Advantages High load capacity Quick attachment and release Specialist for tilting concrete elements Lifting link with remote release available Small socket diameter with high load capacity Integrated thread protection Lifting loops are available as an inexpensive lifting link Lifting link/clutch DEHA 04 Rd 20 Recess former/ Identification cap Transport anchor Material (Anchor) Steel A4 Load classes 1,3 to 45,0 1,3 to 26,0 1,3 to 25,0 0,5 to 12,5 58

59 Transport anchor systems HALFEN Accident recovery system HALFEN ACCIDENT RECOVERY SYSTEM The accident recovery unit is installed as a precautionary measure in road tunnels. In the event of an accident crashed vehicles can be recovered quickly and effectively. 20 Increasingly, emergency and accident recovery services demand that suitable accident recovery units are installed every 100 metres in suitable recesses in tunnel walls. The HALFEN Recovery anchor system is a cast-in stainless steel spherical head anchor, load class 20,0, with a freely pivoting standard lifting link attached. The lifting link is similar to the type used for moving precast concrete elements. A securing bolt is provided to prevent unintentional removal of the lifting link. Recommendation: A chain welded to the anchor plate protects the clutch from theft. Load device with pre-drilled hole (Universal head lifting clutch ), not illustrated: locking pin HALFEN ACCIDENT RECOVERY ANCHOR FOR USE IN ROAD TUNNELS Description / Components HALFEN Article name HALFEN Order number Spherical head transport anchor, stainless steel, load class 20, , A Recess former round, with threaded rods and wing-nut , Load device with provision for locking pin to prevent unintentional removal (without chain) Chain (to prevent unauthorized removal) Provided by customer Anchor plate with bolt anchor/u-shaped bar, weldable Provided by customer The recess formers are reusable. Please order as many as needed for one concreting section. Wall recess with accident recovery anchor and clutch HALFEN Accident recovery system (Transport anchor with installed clutch) 59

60 REFERENCES/PROJECTS Tunnel projects with HALFEN products A SELECTION OF TUNNEL PROJECTS WITH HALFEN PRODUCTS GERMANY Elbtunnel 4 th tunnel tube Suburban railway tunnel, Hamburg Herrentunnel, Lübeck Service tunnel, Uniklinik Eppendorf Road tunnel, Hemelingen Katzenbergtunnel U 2 Suburban rail Pragsattel B10 Stuttgart Hornberg Tunnel Neu-Ulm 21 Stuttgart 21 Schwarzkopftunnel Noise protection enclosure, Hösbach Audi Tunnel, Ingolstadt Tunnel, Geisberg Tunnel, Frankfurter Kreuz North and South Wandersmanntunnel Tunnel, Breckenheim Tunnel, Idstein Tunnel, Montabaur Suburban rail, Ostentor/Dortmund Relief road tunnel, Gevelsberg Suburban rail system, Bochum Suburban rail system, Dortmund Noise protection enclosure A2, Gelsenkirchen-Erle Lange Issel Tunnel Troisdorf Tunnel, ICE (Intercity route) Siegauen Tunnel, ICE (Intercity route) Dickheck Tunnel, ICE (Intercity route) Wahnscheid Tunnel, ICE (Intercity route) Himmelberg Tunnel, ICE (Intercity route) Rottbitze Tunnel Aegidienberg Tunnel Ittenbach Tunnel Günterscheid Tunnel Underground 3, Nürnberg Underground, Fürth Lehrter Railwaystation Tunnel, Berlin Tram tunnel, Railwaystation, Rostock Motorway tunnel, BAB 113 Ems Tunnel / Leer Underground, Düsseldorf Tunnel, Farchant A95 Tunnel, Allach Underground, Munich Underground, Hamburg BELGIUM Tunnel, Antwerp ASDAM-HAST Tunnel, Zelzate-Knokke Antwerp underground Tunnel de Cointe, Liège Tunnel E5/E9, Liège Antwerp Metro Brussels Metro Cointe Tunnel Tunnel, Gestel Rolo Tunnel CEE Tunnel, Brussels Kennedy Tunnel, Antwerp Chaleroi Metro LUXEMBURG Tunnel de Gousselerbierg Tunnel de Markusbierg Tunnel Howald ITALY Variante di valcio autostrada FI-BO Tunnel at Caselle Airport Tunnel Monte Bianco SWITZERLAND Tunnel de Sauges, A5, Neuchatel Connecting tunnel Bettmerhorn-Fischeralp Quarten Tunnel A3 Eggflue Tunnel J18 Utlisberg Tunnel A4 Hauenstein Tunnel Metro Alpine Tunnel Rosenberg Tunnel, St.Gallen Islisberg Tunnel Hafnerberg Tunnel Chienberg Tunnel Seelisberg Tunnel Lötschberg Tunnel Gotthard Base Tunnel NETHERLANDS Zeeburg Tunnel, Amsterdam Sophia Tunnel Tunnel, Pannerdens Kanaal Geldersepoort Schiphol Tunnel Heijnenoord Tunnel Wijker Tunnel AUSTRIA Chain of tunnels, Semmering Chain of tunnels, Kalus Phyrna Motorway Plabutsch Tunnel Karawanken Tunnel, Kärnten Inntal Tunnel Sausenstein Tunnel Vienna Metro CZECHIA Tunnel Praha-Mrazovka Tunnel Jihlava / Circular relief road Motorway tunnel Prag-South Bohemia SWEDEN Södra Länken, Tunnel near Stockholm Railway Tunnel, Malmö Hallands Tunnel (Railway) GREAT BRITAIN Channel Tunnel Tunnel A1, Hatfield FRANCE Paris Metro Lille Metro Eurotunnel, Calais Tunnel de Villejust Tunnel du Puymorens Tunnel de l Épine Tunnel du Landy Tunnel de Tartaiguille Tunnel du Prado-Carenge SINGAPORE Circle Line MRT SOUTH KOREA Railway tunnel Seoul-Pusan MALAYSIA Kuala Lumpur Storm Water Management and Road Tunnel FURTHER PROJECTS Metro Cairo, Egypt Metro Taipeh, Taiwan Great Belt tunnel, Denmark Tunnel Route 5, Hongkong Junk Bay Tunnel, Hongkong Riyadh Metro, Saudi Arabia 60

61 Natural Stone Façade Brickwork Support Systems Concrete-Sandwich Façade Suspended Concrete Façade Rod Systems Fixing Systems FAÇADE TECHNOLOGY Reinforcement Systems CONCRETE TECHNOLOGY Lifting Systems Versatile Bolt Connections and Frame Construction INDUSTRIAL TECHNOLOGY Bolts and Accessories Powerclick Framing System Versatile Fixing System FAÇADE TECHNOLOGY SUSPENDED CONCRETE FAÇADES Precast panel anchors: FPA Horizontal anchors: DS, HKZ, ULZ, SPV, HVL, WDK, WDI, HFV Adjustable restraint: LD Parapet corbels: BRA Top fixing dowels: WPA CONCRETE-SANDWICH FAÇADE Sandwich panel anchors: SP-SPA Sleeve sandwich panel anchors: SP-MVA Flat anchors: SP-FA BRICKWORK SUPPORT SYSTEMS Brickwork support: HK5, KM Brackets: HW, KW, KWL Ties for pre-cast lintel: HK5-S, FSW, HSL Cavity wall ties: LSA, HEA, HPV Scaffold anchor: HGA Wall ties: ML, BL NATURAL STONE FAÇADE Body anchor: HRM, HRC, DT, BA, DH Grout-in anchors: UMA, UHA Sub-structure systems: SUK, UKB ROD SYSTEMS DETAN Rod system: S-460 DETAN Rod system stainless steel DETAN Compression rod system CONCRETE TECHNOLOGY FIXING SYSTEMS HALFEN Cast-in Channels: HTA, HZA Balustrade fixings: HGB Profiled sheets fixing channels: HTU Corner guards: HKW DEMU Fixing anchors: T-FIXX, Bolt anchor Lift-Box: HLX Mechanical anchor bolt systems Chemical anchor bolt systems REINFORCEMENT SYSTEMS Physical structural products Balcony connection: HIT Impact sound insulation units: HBB, HTT, HTF, HTPL Reinforcement connections Screw connections: HBS-05 Universal connection: HUC Stud Connector: HSC Reinforcement coupler: MBT Precast Coupler: HEK Loop Box: HLB Rebend connections: HBT Reinforcement technology Anchor rail: HDB Column shoe: HCC, HAB Betojuster: HBJ Shear dowel: HSD LIFTING SYSTEMS Quick coupling systems DEHA Spherical head lifting system: KKT FRIMEDA Lifting anchor system: TPA Threaded lifting systems HD Anchor: HD Fixing anchors: HA INDUSTRIAL TECHNOLOGY VERSATILE BOLT CONNECTIONS AND FRAME CONSTRUCTION Framing channels: HM, HL, HZM, HZL Connecting parts: HVT Powerclick system: HCS Cantilevers: KON Pipe clamps: HRS Pipe supports: HRG, HCS Pipe base: RUK Lift-off safety device: AHS BOLTS AND ACCESSORIES HALFEN Bolts: HS, HSR, HZS Threaded plates: GWP POWERCLICK FRAMING SYSTEM HCS System 63 System VERSATILE FRAMING SYSTEM HALFIX HFX 61

62 HALFEN INTERNATIONAL From the heart of Europe; all over the world In over 60 countries worldwide you can depend on quality; MADE BY HALFEN worldwide. Sales Distributors 62